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SIMATIC Automation System S7-400H Fault-tolerant Systems Preface, Contents Fault-Tolerant Programmable Logic Controllers S7-400H Installation Options Getting Started Installation of a CPU 41x-H Manual S7-400H in Profibus DP Mode System and Operating Modes of the S7-400H Coupling and Synchronizing Using I/O on the S7-400H Communication Functions Configuring with STEP 7 Failure and Replacement of Components During Operation Modifying the System During Operation Synchronization modules S7-400 cycle and reaction times Technical Specifications Appendices This manual has the order number 6ES7988-8HA11-8BA0 Edition 04/2005 A5E00267695-02 Glossary, Index 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Safety Guidelines This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring to property damage only have no safety alert symbol. The notices shown below are graded according to the degree of danger. ! ! ! Danger indicates that death or severe personal injury will result if proper precautions are not taken. Warning indicates that death or severe personal injury may result if proper precautions are not taken. Caution with a safety alert symbol indicates that minor personal injury can result if proper precautions are not taken. Caution without a safety alert symbol indicates that property damage can result if proper precautions are not taken. Attention indicates that an unintended result or situation can occur if the corresponding notice is not taken into account. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notices in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards. Prescribed Usage Note the following: ! Warning This device and its components may only be used for the applications described in the catalog or the technical description, and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly as well as careful operation and maintenance. Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Copyright Siemens AG 2005 All rights reserved Disclaim of Liability The distribution and duplication of this document or the utilization and transmission of its contents are not permitted without express written permission. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Bereich Automation and Drives Geschaeftsgebiet Industrial Automation Systems Postfach 4848, 90327 Nuernberg Siemens Aktiengesellschaft Siemens AG 2005 Technical data subject to change. 6ES7988-8HA11-8BA0 Preface Purpose of the manual This manual represents a useful reference and contains information on operating options, functions and technical data of the S7-400H CPU. For information on installing and wiring those and other modules to install an S7-400H system, refer to the S7-400 Programmable Controllers, Installation manual. Basic knowledge required A general knowledge of automation technology is considered essential for the understanding of this manual. We presume that the readership has sufficient knowledge of computers or equipment similar to a PC, such as programming devices, running under the operating system Windows 2000 or XP. An S7-400H is configured using the STEP 7 basic software, and you should thus be familiar in the handling of this software. This knowledge is provided in the Programming with STEP 7 manual. In particular when operating an S7-400H system in safety areas, you should always observe the information on the safety of electronic control systems provided in the appendix of the S7-400 Programmable controllers, Installation manual. Validity of the manual The manual is relevant to the following components: • CPU 414-4H 6ES7 414-4HJ04-0AB0 withfirmware version V4.0.x or higher • CPU 417-4H 6ES7 417-4HL04-0AB0, with firmware version V4.0.x or higher Versions required or order numbers of essential system components System component Version required or order number STEP 7 V 5.2 SP1 HF3 with HW update External master on PROFIBUS DP CP443 5 E CP443-5 Extended t d d Order no. 6GK7 443-5DX02-0XE0, hardware version 2 or higher, and firmware version 3.2 or higher Order no. 6GK7 443-5DX03-0XE0, hardware version 1 or higher, and firmware version 5.0 or higher Order no. 6GK7 443-5DX04-0XE0, hardware version 1 or higher, and firmware version 6.0.31 or higher Automation System S7-400H Fault-tolerant Systems A5E00267695-02 iii Preface System component Version required or order number Redundant DP slave interfaces IM 153-2 and IM 153-2FO IM 153-2: 6ES7 153-2AA02-0XB0, version 7 or higher IM 153-2: 6ES7 153-2BA00-0XB0, version 1 or higher IM 153-2FO: 6ES7 153-2AB01-0XB0, version 6 or higher IM 153-2FO: 6ES7 153-2AB02-0XB0, version 1 or higher DP/PA Coupler or Y-Link IM 157 6ES7 157-0AA81-0XA0, version 1 or higher, and firmware version 3.1 6ES7 157-0AA82-0XA0 version 1 or higher, and firmware version 4.0 Communication module CP443-1 (Industrial Ethernet, TCP / ISO ttransport) t) 6GK7 443-1EX10-0XE0, hardware version 1 or higher, and firmware version V2.5.5 Communication module CP443-5 Basic (PROFIBUS; S7 communication) 6GK7 443-5FX01-0XE0, hardware version 2 or higher, and firmware version V2.3.2 6GK7 443-1EX11-0XE0, hardware version 1 or higher, and firmware version V2.5.5 Notice There may be further restriction for various modules. Refer to the information in the corresponding product information and FAQs, or in SIMATIC NET News. Installing the STEP 7 hardware update In addition to STEP 7, you also need a hardware update. You can download the update files directly from the STEP 7 pages on the Internet. To install the updates, select STEP 7 --> Configure Hardware , then select the Options --> Install Hardware Updates command. Certification For details on certifications and standards, refer to the S7-400 Programmable Controllers, Module Data manual, chapter 1.1, Standards and Certifications. Place of this documentation in the information environment This manual can be ordered separately under order no. 6ES7988-8HA11-8AA0. It is also supplied in electronic format on your ”STEP 7” product CD. iv Automation System S7-400H Fault-tolerant Systems A5E00267695-02 Preface Online Help In addition to the manual, detailed support on how to use the software is provided in the integrated Online Help system of the software. The Help system can be accessed using various interfaces: • The Help menu contains several commands: Contents opens the Help index. The Help on H-systems is found under Configuring H-Systems. • Using Help provides detailed instructions on using the Online Help system. • A context-sensitive Help provides information on the current context, for example, on an open dialog box or an active window. You can call this help by clicking ”Help” or using the F1 key. • The status bar represents a further form of context-sensitive Help. It shows a short description of each menu command when you place the mouse pointer over a command. • A short info is also shown for the toolbar buttons when you hold the mouse pointer briefly over a button. If you prefer to read the information of the Online Help in printed form, you can print individual topics, books or the entire Help. Finding Your Way To help you find special information quickly, the manual contains the following index tools: • The manual starts with atable of contents and an index of pictures and tables your manual contains. • The left column on each page of the chapters provides overview of the contents of each section. • The appendices are followed by a glossary which defines important special terminology used in this manual. • At the end of the manual you will find an index which allows quick access to relevant information. Automation System S7-400H Fault-tolerant Systems A5E00267695-02 v Preface Recycling and Disposal The S7-400Hsystem contains environmentally compatible materials and can thus be recycled. For environmentally compliant recycling and disposal of your old device, contact a certified recycling company for electronic waste. Further Support If you have any technical questions, please get in touch with your Siemens representative or agent responsible. You will find your contact person at: http://www.siemens.com/automation/partner You will find a guide to the technical documentation offered for the individual SIMATIC Products and Systems here at: http://www.siemens.com/simatic-tech-doku-portal The online catalog and order system is found under: http://mall.automation.siemens.com H/F Competence Center The H/F Competence Center at our Nuremberg location offers a special workshop with the focus set on redundant SIMATIC S7 automation systems. The H/F Competence Center also offers configuration and commissioning support, and help in finding solutions for problems at your plant. Phone: +49 (911) 895--4759 Fax: +49 (911) 895--4519 e-mail: HF--CC@siemens.com Training Centers Siemens offers a number of training courses to familiarize you with the SIMATIC S7 automation system. Please contact your regional training center or our central training center in D 90327 Nuremberg, Germany for details: vi Telephone: +49 (911) 895-3200. Internet: http://www.sitrain.com Automation System S7-400H Fault-tolerant Systems A5E00267695-02 Preface Technical Support You can reach the Technical Suport for all A&D products • Via the Web formula for the Support Request http://www.siemens.com/automation/support-request • Phone: + 49 180 5050 222 • Fax:+ 49 180 5050 223 Additional information about our Technical Support can be found on the Internet pages: http://www.siemens.com/automation/service. Service & Support on the Internet In addition to our documentation, we offer our Know-how online on the internet at: http://www.siemens.com/automation/service&support where you will find the following: • The newsletter, which constantly provides you with up-to-date information on your products. • The right documents via our Search function in Service & Support. • A forum, where users and experts from all over the world exchange their experiences. • Your local representative for Automation & Drives. • Information on field service, repairs, spare parts and more under “Services”. Automation System S7-400H Fault-tolerant Systems A5E00267695-02 vii Preface viii Automation System S7-400H Fault-tolerant Systems A5E00267695-02 Contents 1 2 3 4 Fault-Tolerant Programmable Logic Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 Redundant Programmable Logic Controllers in the SIMATIC Series . . . . 1-2 1.2 Increasing System Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 S7-400H Installation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 Rules for the assembly of redundant stations . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.2 Base System of the S7-400H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.3 I/O Modules for S7-400H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.4 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.5 Tools for Configuration and Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2.6 The user program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.7 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.2 Hardware installation and S7-400H commissioning . . . . . . . . . . . . . . . . . . . 3-3 3.3 Examples of the reaction of the redundant system to faults . . . . . . . . . . . . 3-5 Installation of a CPU 41x-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Control and display elements of the CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.2 Monitoring functions of the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.3 Status and error displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.4 Reading service data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 4.5 Mode selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.6 Protection Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 4.7 Operating Sequence for Memory Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 4.8 Expanding Load Memory with Memory Cards . . . . . . . . . . . . . . . . . . . . . . . 4-16 4.9 Multipoint Interface (MPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 4.10 PROFIBUS DP Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 4.11 Overview of the parameters of the S7-400 CPUs . . . . . . . . . . . . . . . . . . . . 4-23 Automation System S7-400H Fault-tolerant Systems A5E00267695-02 ix Contents 5 S7-400H in Profibus DP Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 5.1.1 5.1.2 5.1.3 CPU 41x-H as PROFIBUS DP master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DP address areas of 41xH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41xH CPU as PROFIBUS DP master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics of a 41xH CPU operating as PROFIBUS DP master . . . . . . . 5-2 5-3 5-3 5-6 5.2 5.2.1 5.2.2 5.2.3 Consistent Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Consistency of communication blocks and functions . . . . . . . . . . . . . . . . . Access to the Working Memory of the CPU . . . . . . . . . . . . . . . . . . . . . . . . . Consistency rules for SFB 14 ”GET” or reading tag and SFB 15 ”PUT” or writing tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading Data consistently from a DP Standard Slave and Writing Consistently to a DP Standard Slave . . . . . . . . . . . . . . . . . . . . . . . . Consistent Data Access without the Use of SFC 14 or SFC 15 . . . . . . . . 5-11 5-12 5-13 5-14 5-16 System and Operating Modes of the S7-400H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2 States of the S7-400H system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 Operating states of the CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STOP operating state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTUP operating state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COUPLING and UPDATE operating states . . . . . . . . . . . . . . . . . . . . . . . . . Operating State RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOLD operating state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING operating state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6-7 6-8 6-9 6-9 6-10 6-11 6.4 Self-test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 6.5 Time--based reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.6 Evaluation of process alarms in the S7-400H System . . . . . . . . . . . . . . . . 6-16 Coupling and synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1 Effect of coupling and update operations . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.2 Conditions of coupling and updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.3 7.3.1 7.3.2 7.3.3 7-4 7-8 7-10 7.3.4 Coupling and update operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupling sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Update sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changeover to the CPU which contains the modified configuration or memory expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disabling coupling and update operations . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 7-16 7.4 7.4.1 7.4.2 7.4.3 7.4.4 Time monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time--based reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ascertaining the monitoring times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Influences on time--based reactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance values for coupling and update operations . . . . . . . . . . . . . . 7-17 7-19 7-20 7-27 7-28 7.5 Special features in coupling and update operations . . . . . . . . . . . . . . . . . . 7-29 5.2.4 5.2.5 6 7 x 5-13 Automation System S7-400H Fault-tolerant Systems A5E00267695-02